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Volume 8, Issue 4, Spring2014

3D Grading and Pattern Unwrapping Technique for Loose-fitting Shirt


Part 1: Resizable Design Template
Abu Sadat Muhammad Sayem
The Clothing Technology Centre, The Clothing Institute, Dhaka
&
Textile Engineering
Southeast University, Bangladesh
Richard Kennon
Textiles & Paper, School of Materials
Manchester
United Kingdom
Nick Clarke
Textiles & Paper, School of Materials
The University of Manchester
United Kingdom
ABSTRACT
This paper describes the Reverse Engineering (RE) and 3D modelling techniques used to develop
a novel resizable design platform for use in virtual design; pattern flattening and automatic
grading of mens upper-body outerwear. Advanced body scanning technology and RE technique
are applied to extract a set of sectional curves. The extracted curves are further processed in a
CAD software program and used for new surface generation by applying a 3D modelling
technique to form a resizable design platform, which is intended to be used as a 3D drawing
board for the creation of virtual shirts and for the execution of 3D grading and automatic pattern
flattening. As far as can be ascertained, such a resizable design platform for combined virtual
design, automatic pattern creation and 3D grading of mens shirt has not been previously
demonstrated.

Keywords: Virtual shirt; resizable template; pattern flattening; 3D grading

Introduction decade (McCartney et al., 2000; Kim &


Kang, 2002; Wang, Smith & Yuen, 2002;
An emerging technique for clothing pattern Wang, Wang & Yuen, 2002; Sayem, 2004;
creation is that of 3D to 2D pattern Petrak & Rogale, 2006; Petrak, Rogale &
unwrapping which means the automatic Mandekic-Botteri, 2006; Decaudin et al.,
generation of 2D patterns by unwrapping or 2006; Kim and Petrak, 2007; Fang & Ding,
flattening the 3D design. Notable research 2008; Fang, Ding & Huang, 2008 and
has been carried out in this field in the last Roedel, 2008). However this technology is

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not equally advanced and sufficiently This paper presents a technique for
mature for both intimate wear and outerwear developing a resizable design template that
to be implemented in the industry at this uses traditional size charts including ease
point of time (Sayem, Kennon & Clarke, distribution over the girth measurements for
2010 and 2012). A few clothing CAD the purposes of 3D grading and pattern
systems such as 3D Interactive software flattening of loose-fitting shirt.
from TPC (Hong Kong) and 3D Runway
from OptiTex International (Israel) provide Methodology
the capability to execute pattern
unwrapping, but in a very limited context The proposed resizable design template was
and only for close-fitting garments. No intended to be structured around a set of
efficient solution is available for outerwear, sectional curves, which are representative of
which encompasses the major portion of the size parameters. These sectional curves
clothing consumption worldwide. For are extracted from a virtual model
example, it was 88% of total clothing constructed from a set of Point-Cloud data
consumption in the 27 member states of the captured from a full-body scan of a mature
European Union in 2007 and worth of 260 male subject using NX16 body scanning
billion (CBI, 2008). system from [TC2] (Textile/Clothing
Technology Corporation), USA. The process
Attempts to design virtual outerwear for the followed to develop a resizable shirt
purposes of pattern flattening were made by template is summarized in Figure 1 and
Hinds and McCartney (2000), McCartney et explained in the following sections.
al. (2000), Wang, Wang and Yuen (2002),
Petrak and Rogale (2006), Petrak, Rogale CAD Model from Point-Cloud
and Mandekic-Botteri (2006), Kim and The raw scan data processed by the NX16
Park (2007), Yunchu and Weiyun (2007) analytical software as a refined body model
and Siegmund et al. (2010). All of their in .rbd file format was converted into a
works followed laborious routes to triangulated body model in .obj data
incorporate variable ease at different places format having approximately 110,000
between the virtual body and the garment triangles before importing into a reverse
panels for outerwear. None of their engineering (RE) software. Using an
techniques consider ease distribution over appropriate RE software, the triangulated
the girth measurements as practically body model was converted into a CAD
followed in the fashion industry during model (Figure 2) having approximately
pattern creation for outerwear. 400,000 mesh triangles and this model was
further used for extracting the sectional
curves from it.

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Body scanning

Generate CAD model from


Point-Cloud

Slice the CAD model to extract sectional curves from


body and arms

Generate modified B-Splines to form body and sleeve shapes


of a male upper body outerwear garment

Halve the body curves vertically and Duplicate the sectional curves
generate mirror image curves of the one of one sleeve as a mirror
halves to create symmetrical curves image to the other side

Scale the body and sleeve curves

Generate new surfaces from the scaled curves to develop the


Resizable Shirt Template

Figure 1. Workflow for Resizable Shirt Template

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Point-Cloud Polygonal Phase CAD Model

Figure 2. Virtual Model of a Male Subject

Sectional Curve Extraction torso, as can be seen in Figure 3. The


European Standard for size designation of
i) Curves from torso clothes EN 13402-1:2001 was consulted
Seven sectional curves namely neck girth, to identify the landmark positions of the four
lower neck girth, shoulder girth, chest girt at primary sectional curves representative of
armpit, chest girth at the fullest area, waist the neck girth, chest girth, waist girth and
girth and hip girth were extracted from the hip girth.

Figure 3. The Extracted Sectional Curves

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The measurements of waist girth and hip position of the arm girth measurements.
girth are not directly used in the traditional However, with the availability of body scan
pattern cutting system for mens shirts data, it is possible to specify and take
(Aldrich 1990). However, the position of the advantage of non-standard anatomical
waist line is important for shaping and measurements, as they can offer useful
tailoring the middle part of the body of shirts secondary measurements. The forearm girth
and jackets (Aldrich 1990). The waist girth was located on the fullest area below the
curve was selected in this work with the aim elbow, and the upper arm girth on bicep was
of maintaining an option to produce a located at approximately 5 cm above the
tailored silhouette of mens shirts on the elbow joint. Later, an additional curve,
proposed design template; and the hip girth termed here as curve TS, was extracted
curve was selected as its lower end contour. from the shoulder curve to define the upper
edge of the each sleeve, as can be seen in the
In addition to the four primary sectional Figure 5.
curves, three secondary curves (two for the
neck to shoulder area and one for the chest Modified Curves Generation
area) were found to be necessary to
accurately reproduce the geometry of upper The sectional curves, which are stored as an
body garments. These girth measurements IGES data format, were imported into an
are not traditionally used as size parameters, advanced 3D CAD software package.
because they do not correspond with easily Naturally, these curves represent the surface
identifiable anatomical landmarks. As a geometry of a scanned subject, but do not
result, no available standard describes their necessarily provide a satisfactory shape for
positions on the torso. For rebuilding the the surface geometry of an outerwear
neck to shoulder area, two secondary girth garment. Furthermore, they were found to be
curves, namely the lower neck girth and the broken in some places due to limitations of
shoulder girth were incorporated. The the scanning and modelling processes. Using
shoulder girth curve was located at the curve drawing tool of the CAD system,
approximately 1 cm below the crown of the continuous B-spline curves were generated
shoulder on either side of the torso. The from each of the sectional curves by
lower neck girth is designated as being 3 cm removing the irregularities in the extracted
above the shoulder girth. To rebuild the curves such as concave areas due to the
geometry of the chest area, a second girth natural geometry of the human body (for
measurement at the fullest chest area was example the spinal cord line at the back of
selected. the torso) and by taking the geometry of
mens upper body outerwear into account.
ii) Curves from arm
In order to develop the sleeves of the While drawing the modified neck girth, the
proposed 3D template, four curves, namely: protruding parts at the front due to the
the upper arm girth, the arm girth on bicep, laryngeal prominence were avoided as well
the forearm girth and the wrist girth were as the concave segments both at the front
used. Of these, only the wrist girth is and back which were smoothed out. The
sometimes used as a size parameter in lateral concave segments of the lower neck
traditional pattern cutting systems (Aldrich, girth curve were also smoothed out in the
1990). The other measurements do not newly drawn modified curve. These
correspond to easily-defined anatomical modified curves are illustrated in Figure 4.
landmarks; they do not lend themselves to Similarly modified curves for the chest girth
repeatable manual measurement. at the fullest area, waist girth and hip girth
Consequently, no size standard describes the are drawn.

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Extracted neck Newly drawn
Newly drawn Extracted
girth curve lower neck girth
neck girth lower neck
curve
curve girth curve

Figure 4. Modified Neck Girth and Lower Neck Girth Curves Generation
Symmetrical Curves Generation to the right side, and each of the left halves
were joined with its respective mirrored
The human body is not a symmetrical curves to form completely closed and
object, so the curves that are derived from it continuous curves. This generates fully
inevitably lack symmetry. Even the newly symmetrical body curves (see Figure 5).
drawn modified curves inherit visible These symmetrical curves were further used
asymmetry from their parent curves. in the subsequent steps of the process.
However, mass-produced clothing is
expected to have a symmetrical structure if In order to ensure the symmetry of the
intentional asymmetry has not deliberately proposed 3D design template, the modified
introduced by designers. This required the sleeve curves from the left side are mirrored
curves to be modified to meet the purpose. to build the respective curves for the other
The body curves were split into two halves side, hence creating symmetrical curves for
based on a vertical plane, and one set of the right and left sleeves (Figure 5).
halves (the left halves) are mirror-duplicated

Curve TS
within the
Shoulder Curve

Figure 5. Symmetrical Body and Sleeve Curves

Waist and Hip Curves Selection generating a surface out of them. The
surface generation process is further
Before scaling the curves to ensure the discussed in a later section. The qualitative
resizeability of the proposed shirt template, ability of the body curves to form
these symmetrical curves were first tested by appropriate geometry of a mens shirt is

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dealt here. A close review of the curves convex outline at the front and a concave
representing the chest girth at the fullest outline at the back, when seen from the
area, waist girth and hip girth; reveals sides. To address this problem, the waist
significant differences in their shape and curve and hip curve were replaced by
depth. They do not produce a good body duplicated copies of the chest curve.
shape to represent as a standard shirt Because they utilize the same curve
geometry, as can be seen in Figure 6. The geometry, they form a uniform body shape
resultant shape from these three curves has a as can be seen in Figure 6.

Figure 6. Curve Replacement and the produced Shape

For the scaling and final surface generation involves the creation of two length
processes, the duplicated copies of the chest parameters for each curve, selection of a
curve were used instead of the waist and hip scaling point for each curve and inputting
curves and they will be hereafter described one or more scaling factors for each curve.
as waist and hip curves due to the locations As a part of the scaling process, all of the
in which they are used. modified and symmetrical body and sleeve
curves are first defined as length parameters.
The Scaling Process Similarly, for each of the curves, an
additional parameter is defined to facilitate
The scaling process forms the basis of the acceptance of external values from a size
automatic 3D grading for the parametric 3D table for the purpose of resizing or grading.
shirt template which can be used for the Designations of the length parameters are
creation of a virtual shirt and for the summarized in Tables 1 and 2. To make the
extraction of 2D patterns pieces using a scaling process functional it is necessary to
flattening technique. The scaling procedure link the set of second length parameters with

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external size databases for importation of necessary values whenever required.

Table 1 List of Parameters and Scaling Factors for Body Curves


Parameter
Parameter
Names of The Designation for
Designation for Scaling Factor (A'/A)
Curves External Values from
Existing Length (A)
Size Table (A')
1 Neck Girth Ng Ng_ST Ng_ST/Ng
Lower Neck
2 LNg LNg_ST LNg_ST/LNg
Girth
3 Shoulder Girth Sg Sg_ST Sg_ST/Sg
Chest Girth at
4 Cg_ap Cg_ap_ST Cg_ap_ST/Cg_ap
Armpit
Chest Girth at
5 Cg Cg_ST Cg_ST/Cg
the Fullest Area
6 Waist Girth Wg Wg_ST Wg_ST/Wg
7 Hip Girth Hg Hg_ST Hg_ST/Hg
Centre Length
8 CL CL_ST CL_ST/CL
(Shirt Length)

Table 2 Lists of Parameters and Scaling Factors for Sleeve Curves


Parameter
Parameter
Names of The Designation for
Designation for Scaling Factor (A'/A)
Curves External Values from
Existing Length (A)
Size Table (A')
1 Curve TS Ts Ts_ST Ts_ST /Ts
Upper Arm
2 UAg UAg_ST UAg_ST /UAg
Girth
Arm Girth at
3 Ag_b Ag_b_ST Ag_b_ST /Ag_b
Bicep
4 Forearm Girth Fag FAg_ST FAg_ST /Fag
5 Wrist Girth Wrg Wrg_ST Wrg_ST /Wrg
6 Sleeve Length SL SL_ST SL_ST/SL

The scaling factors for each of the curves are The subsequent step involves selecting
defined as A'/A as can be seen in Tables 1 scaling points for each of the curves from
and 2, where: which they enlarge or diminish themselves;
A' = the value of a desired size of it was also necessary to incorporate into the
girth curve; and software a scaling factor, so that the
A = the existing circumferential value program would be able to determine the
of that girth curve. extent of the enlargement and diminution of
The value of the desired size for each curve each curve during resizing and grading. To
equates to the size measurement for a implement this process within the CAD
particular type of clothing. system in use, the scaling options include

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scaling from point and/or scaling with
three factors.
i) Scaling the Body Curves parameters for each of the body curves are
listed in Table 1. The body curves, with the
For the purpose of scaling, the body curves exception of the hip curve, are scaled only in
were divided into two groups: a) shirt the horizontal plane (i.e. + X and + Y axis)
length-independent curves (neck, lower with a single factor for each of the curves.
neck, shoulder, chest and waist curves), and For the neck curve, for example, Ng
b) length-dependent curves (hip curve). As represents its original length which was
clothing size tables are developed within the 402.72 mm; and Ng_ST represents the value
standard height groups (Aldrich 1990), it is for resizing it, which would be input through
assumed that the neck, lower neck, shoulder, an Excel size table. If the value of Ng_ST
chest and waist curves, which are not was 450mm, for example, the scaling factor
dependent on the shirt length, require (A'/A) would be 450/402.72 (=1.12). Using
scaling only in the horizontal plane. the appropriate scaling tool from the 3D
However, for the hip curve, it is also CAD system in use, the neck curve would
necessary to scale in the vertical plane to be scaled from the pre-determined point,
ensure that the change in shirt length is shown in Figure 7, with a factor of
executed as per designers and customers Ng_ST/Ng, which was in this case 1.12.
requirements. However, the value of the scaling factor is
variable depending on the value of Ng_ST
The middle point of the lines joining the from the size tables. Similarly all of the
front and back part of each curve, as can be body curves except the hip curve are scaled
seen in Figure 7, were selected as scaling with their respective factors as expressed in
points for all the body girth curves except Table 1.
the hip curve. Designations of two

Scaling Factor (A'/A) for the Neck Curve,


= Ng_ST/Ng = 450/402.716540702 1.12

Scaled Neck Girth Curve

Scaling Point

Original Neck Girth Curve

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The hip curve defines the lower end contour vertical line from the center of the neck to
of the proposed shirt template. As the length the hip curve, as shown in Figure 8, and
of the mens shirt can vary with the size scaled with a factor (A'/A) of CL_ST/CL as
change or within the same size depending on described in Table 1. The hip curve is then
the design, the position of the scaled hip scaled from the upper end point of the scaled
curve should vary in the vertical plane (i.e. center length line as shown in Figure 8 and
according to the change in shirt length). In with the factor CL_ST/CL for the +Z
order to relate the hip curve with the shirt direction and with the factor Hg_ST/Hg for
length, the shirt length is first defined as a the + X and + Y directions.

Figure 8. Scaling the Hip Curve

The lower neck curve is essentially used to LNg_ST = Ng_ST x LNg/Ng


reproduce the neck to shoulder geometry
appropriately. However, this is not a So the system will calculate the value of
standard measurement location from the LNg_ST (the value of the lower neck girth
clothing manufacturing point of view. To used for resizing the template) based on the
reduce the number of parameters in the size value of Ng_ST (the value of the neck girth
table, this girth measurement is not from the size table) as a factor of LNg/Ng
considered as a direct size parameter for the (the ratio of the original length of the lower
proposed shirt template. Rather it is linked neck girth to the original length of the neck
to the neck girth using the following girth). As a result the size change of the
expression: lower neck girth will always be dependent
on the size change of the neck girth.

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ii) Scaling the Sleeve Curves the front and back parts of the chest girth at
the armpit level and the shoulder girth
Similarly to the body curves, the sleeves
curves respectively. The curve TS and the
curves are also divided into two categories,
upper arm curve were scaled on the
denoted as: a) sleeve length-independent
horizontal plane based on the factors
curves (curve TS, upper arm, arm girth at
described in Table 2. Similarly, the curves
bicep, forearm curve); and b) sleeve length-
representing arm girth at the bicep and the
dependent curves (the wrist curve).
forearm girth were scaled on the horizontal
Designations of two parameters for each of
plane, but the scaling points were taken as
the sleeve curves are listed in Table 2. For
the middle points of the lines joining the
the upper arm curve and for the curve TS
curves from the left and right sleeves, as can
representing the upper edge of the sleeve,
be seen in Figure 9.
the middle points of the halving lines joining

Scaling point for sleeve line


Scaling point
. for 2nd scaling
of wrist curve
.
Sleeve line

Scaling point for arm curve at bicep

Scaled sleeve line


Scaling point for forearm curve

1st scaled Scaling point


wrist curve for 1st scaling
of wrist curve

Step 1
2nd scaled
wrist curve

Step 2
Figure 9 Scaling of the Wrist Girth Curve

To ensure that the change in sleeve length the wrist curve was scaled in the horizontal
corresponds with the change in clothing size plane from the middle point of the line
or design, the wrist curve was scaled along joining the left and right wrist curves. The
both the horizontal and vertical planes. The newly scaled wrist curve was scaled again in
procedure was completed in two steps, the vertical plane, based on using the end
which are illustrated in Figure 9. Initially, point of the scaled sleeve line as a scaling

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point, as can be seen at the left side of subject from which the scan data were
Figure 9. The twice-scaled wrist curve (the generated and from which the subsequent
second scaled in Figure 9 was finally used in body model was developed, had a chest
the surface generation process described in measurement and a waist measurement close
the next section. As a result, the scaled wrist to that described by Aldrich (1990) for this
curve changes its size based on the change size.
of its value in the size table and also changes The size table was split into sub-databases
its position based on the change in sleeve for individual sizes with appropriate ease
length in the size table. allowances. A minimum functional ease of
7.5 cm for the chest area was selected
Similarly to the creation of the lower neck following the findings of Moll and Wright
curve described in previous section, the (1972) and a design ease of 8.5 cm was
curve TS does not represent a standard selected to make a total ease of 16 cm which
measurement location from the clothing corresponds to the suggested ease around the
manufacturing point of view. To reduce the chest (without a seam allowance) for easy-
number of parameters in the size table, it is fitting mens tee shirts and knitwear, by
linked to the shoulder girth using the Aldrich (1990).
following expression:
When creating a straight side-seam
Ts_ST = Ts/Sg x Sg_ST silhouette for a mans shirt, sufficient ease
allowances for the waist girth and hip girth
So the system will calculate the value of were selected to keep the final
Ts_ST based on the values of the parameters measurements equal across the chest area.
Ts, Sg and Sg_ST, where the value of Although no circumferential expansion takes
Sg_ST will be input from size tables and the place in the arms as it does for the chest and
values of Ts and Sg are presented to the waist areas due to the breathing mechanism,
system as length parameters. sufficient functional ease is required in the
sleeves to allow for unhampered arm
Developing Size Databases for 3D Grading movement. The size parameters with ease
allowances for size 42 are included in Table
A database of sizes from 37 to 45 for mens 4. The same ease allowances have been
shirts has been developed using the MS included for other sizes, namely 37, 38, 39,
Excel spreadsheet program, as detailed in 40, 41, 43, 44 and 45 for this work.
Table 3. The values for neck girth, chest However, it has to be noted that the size
girths, waist girth, hip girth and wrist girth databases and values of ease for each
were taken from the standard body measurement point may be altered in the
measurements for mature figures of standard databases to meet the designers and
males described by Aldrich (1990) in the customers requirements. Once all the size
second edition of the book Metric Pattern tables with ease allowances had been
Cutting for Menswear. The values for the prepared in Excel spreadsheets, they were
shoulder girth, upper arm girth, arm girth at programmed, by assigning parameter
the bicep and forearm girth are not available designations to the corresponding cells
in any traditional size tables. For the containing size parameters, to be linked with
shoulder girth, upper arm girth, arm girth at the 3D grading process using the Excel
the bicep and forearm girth, the link facility within the 3D CAD software
measurements extracted from the scan data, suite used in this research so that they can be
which have been used throughout this work, imported, as required, to support automatic
were selected for use in the size table as the grading.
measurement for size 42, because the

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Table 3 Size Table for Mens Tee-Shirt
Measurements for Mens Shirts (without ease) in cm
Size Parameter (neck size as size designation)
37 38 39 40 41 42 43 44 45
1 Neck Girth 37 38 39 40 41 42 43 44 45
2 Shoulder Girth 87 89 91 93 95 97 99 101 103
3 Chest girth at armpit 88 92 96 100 104 108 112 116 120
4 Chest girth at the fullest area 88 92 96 100 104 108 112 116 120
5 Waist girth 74 78 82 86 90 98 102 106 110
6 Hip girth 92 96 100 104 108 114 118 122 126
7 Upper arm girth 30 31 32 33 34 35 36 37 38
8 Arm girth on bicep 29.5 30.5 31.5 32.5 33.5 34.5 35.5 36.5 37.5
9 Forearm girth 27 28 29 30 31 32 33 34 35
10 Wrist girth 22 22.5 22.5 23 23 23.5 23.5 24 24
11 Shirt Length 76 78 80 81 81 82 82 82 82
12 Long Sleeve Length 87 88 88 89 89 90 90 90 90

Table 4 Size Parameters with Ease Allowance for Size 42


Clothing
Measurement Functional Design
Size Parameter measurement
without ease (cm) Ease (cm) Ease (cm)
(cm)
Neck Girth 42 0 0 42
Shoulder Girth 97 0 1 98
Chest girth at armpit 108 7.5 8.5 124
Chest girth at the fullest area 108 7.5 8.5 124
Waist girth 98 7.5 18.5 124
Hip girth 114 0 10 124
Upper arm girth 34 7 0 41
Arm girth on bicep 33 6.5 0 39.5
Forearm girth 30.5 4.5 0 35
Wrist girth 23.5 2 0 25.5
Shirt Length 82 - - 82
Long Sleeve Length 90 - - 90

Surface Generation to form the 3D Shirt function of the 3D CAD software in use, as
Template illustrated in Figure 10. The newly-
Once all the body and sleeve curves have generated surfaces for the body and sleeves
been scaled, a geometric modelling form the desired shirt template as 3D design
technique was applied to generate a new platform for virtual clothing creation, pattern
surface out of them, employing the curve flattening and automatic grading in 3D as
matching and parametric synchronization can be seen in the Figure 11.
options available within the 3D modelling

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Figure 10. New Surface Generation out of Scaled Body and Sleeve Curves

Figure 11. The Resizable Shirt Template


Conclusions the 3D environment. The template is scaled
with 12 size parameters (7 for body and 5
In this part of the research, a process of for sleeves) represented by construction
developing a 3D shirt template by applying curves. The scaling process forms the basis
reverse engineering and geometric of the parametric 3D shirt template which
modelling techniques, and a novel scaling can used to facilitate automatic 3D grading.
process to make it ready for use in 3D The value of the size parameters i.e. the
grading have been demonstrated. Its length of the scaled curves can be altered
application in virtual design and automatic individually or in group (representing the
pattern flattening are described in part 2 of arm, or the torso for instance) and this
this paper. This shirt template is intended to procedure may be invoked whenever it is
be used as a 3D drawing board for fashion deemed to be necessary, by the designer or
designers to create a virtual shirt directly in by a pattern technician.

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Acknowledgement Science and Technology, 18 (3), pp.
179-187.
We are thankful to the Association of
Commonwealth Universities (ACU) in the Petrak, S.; Rogale, D. and Mandekic-
UK, Lectra (UK), MD3D Ltd (UK) and Botteri, V. (2006). Systematic
Shape Analysis Ltd (UK) for technical representation and application of a 3D
support and friendly co-operation. computer-aided garment construction
method Part II: spatial transformation of
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Article Designation: Refereed 15 JTATM


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Article Designation: Refereed 16 JTATM


Volume 8, Issue 4, Spring 2014

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